I've had problems with cold air pouring in on the passenger's feet since I bought the car and with winter fast approaching I figured I would do a little work to the heater.

First step was to remove the glove box tray so I could get to the heater fan. There are three screws you have to remove. One can be seen in the back of the box and the other two are at the top (hidden in this picture):

Once the tray has been removed you can see a red bar in the middle. The heater is held on by three bolts. The first is on the red bar and the second is to the right:

A good way to get to the third bolt (which is on the bottom right of the heater housing) is by using a long socket extension:

Here you can see the bottom right bolt as well as the control cable which also needs to be removed:

After the bolts and cable have been removed you need to disconnect the two wiring connectors:

Wow, look at all the dirt on the evaporator! I used a wire brush and a vacuum cleaner to remove most of this:

The top of the heater fan box is where the fresh air from the windshield cowl comes in. You can see how bad the foam is:

The foam is also desintegrated on the recirc air door:

You can remove the fan with the three screws:

After the fan has been taken out just unhook the metal clips to split the housing in half:

Once the box has been clamshelled open you can remove the flapper door:

One side of the flapper has a white clip holding it on. Just use a small screwdriver to pry on it:

I used a wire brush to remove the dead foam:

I paid less than $4 for this foam weather stripping at Lowes:

I put the foam on the front and back of the flapper door:

I also put new foam where the box contacts the underside of the windshield cowl (fresh air):

In the stock configuration, the A/C evaporator opening has foam inside of it (I.D.) and the fan box slides into the foam. I removed the foam from the evaporator and put foam around the O.D. of the fan box. You can see I put a piece of electrical tape to keep the foam from sliding off during assembly. Almost all of the role of foam was used during the project:

Note - You are probably seeing missing links to some pictures above. I still use Notepad to create the html code and have a template with plenty of extra references to pictures to save on typing. As I continue the page I will add pictures and descriptions and these missing links will disappear.